激光粉末床熔融飞机系统安装支架轻量化设计与力学分析

韩昌骏; 李恒; 王义; 刘洪添; 蒋睿哲

doi:10.3969/j.issn.1674-6457.2025.11.010

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精密成形工程 ›› 2025, Vol. 17 ›› Issue (11) : 116-125. DOI: 10.3969/j.issn.1674-6457.2025.11.010

先进材料智能成形技术

激光粉末床熔融飞机系统安装支架轻量化设计与力学分析

韩昌骏¹, 李恒¹, 王义¹, 刘洪添¹, 蒋睿哲^2,*

作者信息 +

Lightweight Design and Mechanical Analysis of an Aircraft System Installation Bracket Fabricated by Laser Powder Bed Fusion

HAN Changjun¹, LI Heng¹, WANG Yi¹, LIU Hongtian¹, JIANG Ruizhe^2,*

Author information +

文章历史 +

摘要

目的为实现飞机系统安装支架的轻量化,提出了一种面向激光增材制造的协同优化设计方法。方法基于变密度法（SIMP）建立以最大化结构静力刚度为优化目标的拓扑优化模型,并结合包络优化与形状优化策略构建一体化设计框架;以某型飞机系统安装支架为研究对象,开展多载荷工况有限元分析、拓扑优化与几何重构,同时引入激光粉末床熔融（LPBF）工艺约束,实现结构设计与成形工艺的协同,最终通过LPBF工艺完成实物成形与验证。结果初始支架壁板与悬空区域存在材料冗余与局部应力集中现象,其高达6.3的安全系数表明该结构具有显著减重潜力。据此进行的优化设计,在成功减重15.52%的同时,将最大应力与位移分别控制在34.25 MPa与0.069 mm的较低水平,远低于材料屈服强度且满足安装精度要求,优化后支架的传力路径连续、应力分布均匀。LPBF成形件外形完整、表面质量良好,无裂纹、塌陷及翘曲等缺陷,验证了模型具有良好的工艺可行性。结论本研究方法在保证结构强度与刚度的同时实现了减重,为航空承载构件的轻量化与增材制造一体化设计提供了可验证的设计框架。

Abstract

The work aims to propose a collaborative optimization method for laser additive manufacturing to achieve lightweight design of aircraft system installation brackets. A topology optimization model was developed by the variable density method (SIMP) with the optimization objective of maximizing static structural stiffness, while an integrated design framework was constructed by combining envelope optimization and shape optimization strategies. With a typical aircraft system installation bracket as the research object, systematic investigations including multi-load case finite element analysis, topology optimization, and geometric reconstruction were conducted. Laser Powder Bed Fusion (LPBF) process constraints were incorporated to achieve synergistic optimization between structural design and manufacturing processes. Finally, manufacturing and verification of the physical prototype were completed via the LPBF process. The initial bracket exhibited significant material redundancy and localized stress concentrations in the wall panels and overhanging regions, with a high safety factor of 6.3 indicating substantial weight reduction potential. The optimized structure achieved a 15.52% weight reduction while maintaining maximum stress and displacement at low levels of 34.25 MPa and 0.069 mm, respectively, well below the material yield strength, meeting installation accuracy requirements, with continuous load transfer paths and uniform stress distribution. The LPBF-formed components showed complete geometry and good surface quality, free from defects such as cracks, collapse, or warping, validating the good feasibility of the model. This research achieves significant weight reduction while ensuring structural strength and stiffness, providing a verifiable design framework for integrated lightweight and additive manufacturing design of aerospace load-bearing components.

导出引用

韩昌骏, 李恒, 王义, 刘洪添, 蒋睿哲. 激光粉末床熔融飞机系统安装支架轻量化设计与力学分析[J]. 精密成形工程. 2025, 17(11): 116-125 https://doi.org/10.3969/j.issn.1674-6457.2025.11.010

HAN Changjun, LI Heng, WANG Yi, LIU Hongtian, JIANG Ruizhe. Lightweight Design and Mechanical Analysis of an Aircraft System Installation Bracket Fabricated by Laser Powder Bed Fusion[J]. Journal of Netshape Forming Engineering. 2025, 17(11): 116-125 https://doi.org/10.3969/j.issn.1674-6457.2025.11.010

中图分类号： TG404

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